Sym EuroMX 125 User manual

SERVICE MANUAL
FORWARD CONTENTS
HOW TO USE THIS MANUAL MECHANISM ILLUSTRATIONS

Forward
This service manual contains the technical data of each component
inspection and repair for the SANYANG Euro MX 125 motorcycle.
The manual is shown with illustrations and focused on “Service Procedures”,
“Operation Key Points”, and “Inspection Adjustment” so that provides technician
with service guidelines.
If the style and construction of the motorcycle are different from that of the
photos, pictures shown in this manual, the actual vehicle shall prevail.
Specifications are subject to change without notice.
This manual that contains all data, illustration, indication and specifications
is based on current production information. SANYANG reserves the right to
make changes at any time without notice and without incurring any obligation
whatever. No part of this manual can be duplicated by any means without
written permission of SANYANG.
Service Department
SANYANG Industry Co., LTD.
Home page Contents

How to Use This Manual
This service manual describes basic information of different system parts
and system inspection & service for SANYANG Euro MX 125 motorcycles.
In addition, please refer to the manual contents in detailed for the model you
serviced in inspection and adjustment.
The first chapter covers general information and trouble diagnosis.
The second chapter covers service maintenance and special service tools
information.
The third to the eleventh chapters cover engine, fuel systems and driving
systems.
The twelfth to fifteenth chapters are contained the parts set of assembly
body.
The sixteenth chapter is electrical equipment.
The seventh chapter is for wiring diagram.
Please see index of content for quick having the special parts and system
information.
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Contents
Page Content Index
1-1 ~ 1-16 General Information / Trouble Diagnosis
1
2-1 ~ 2-18 Service Maintenance Information
2
3-1 ~ 3-8 Lubrication System 3
4-1 ~ 4-14 Fuel System 4
5-1 ~ 5-10 Engine Removal 5
6-1 ~ 6-16 Cylinder Head / Valve 6
7-1 ~ 7-8 Cylinder / Piston 7
8-1 ~ 8-14 “V” Type Belt Driving System / Foot-Starter 8
9-1 ~ 9-6 Final Driving Mechanism 9
10-1 ~ 10-10 Alternator / Starting Clutch 10
11-1 ~ 11-6 Crankcase/Crankshaft 11
12-1 ~ 12-14 Body Cover 12
13-1 ~ 13-12 Brake System 13
14-1 ~ 14-8 Steering/Front Wheel/Suspension 14
15-1 ~ 15-4 Rear Wheel/Suspension 15
16-1 ~ 16-22 Electrical Equipment 16
17-1 ~ 17-2 Wiring Diagram 17
Home page

Model illustration
Horn
Spark plug
Engine number
Engine oil drain plug
Light /
Starter switch
High & Low beam /
Passing /
Turn signal /
Horn switch
Exhaust
muffler
Ignition switch
Gear oil drain
plug
Battery / Fuse
IG. Coil /
Start relay
Fuel tank
Oil level
Oil strainer
Front brake
lever
Rear brake
lever
Air cleaner
Gear oil
Inspection plug
Headlight
Front winker light
Tail light
Winker relay AC. Generator
Carburetor
Seat lock
Rear winker light
Frame number
Home page Contents

1. General Information/Trouble Diagnosis
1-1
Symbols And Marks.................. 1-1
General safety........................... 1-2
Service Precautions.................. 1-3
Specifications............................ 1-9
Torque Values (Engine).......... 1-10
Torque Values (Frame) ........... 1-11
Standard Torque Values for
Reference................................. 1-11
Troubles Diagnosis................. 1-12
Parts To Be Greased............... 1-16
Symbols And Marks
Symbols and marks are used in this manual to indicate what and where the special service are
needed, in case supplemental information is procedures needed for these symbols and marks,
explanations will be added to the text instead of using the symbols or marks.
Warning Means that serious injury or even death may result if procedures are
not followed.
Caution Means that equipment damages may result if procedures are not
followed.
Engine oil Limits to use SAE 10W-30 API SG class oil. Warranty will not cover
the damage that caused by not apply with the limited engine oil.
(Recommended oil: KING MATE G-3 oil)
Grease King Mate G-3 is recommended. (KING MATE G-3)
Gear oil King Mate gear oil (SYM HYPOID GEAR OIL ) is recommended.
(SAE 85W-140)
Locking sealant Apply sealant, medium strength sealant should be used unless
otherwise specified.
Oil seal Apply with lubricant.
Renew Replace with a new part before installation.
Brake fluid Use recommended brake fluid “DOT3” or “WELLRUN” brake fluid.
Special tools Special service tools.
correct Meaning correct installation.
wrong Meaning wrong installation.
Indication Indication of components.
directions Indicates position and operation directions.
Components assembly directions each other.
Indicates where the bolt installation direction, --- means that bolt
cross through the component (invisibility).
1
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1. General Information/Trouble Diagnosis
1-2
General safety
Carbon monoxide
If you must run your engine, ensure the place is
well ventilated. Never run your engine in a
closed area. Run your engine in an open area, if
you have to run your engine in a closed area, be
sure to use an extractor.
Caution
Gasoline
Gasoline is a low ignition point and explosive
material. Work in a well-ventilated place, no
flame or spark should be allowed in the work
place or where gasoline is being stored.
Caution
Used engine oil
Caution
Hot components
Caution
Battery
Caution
Brake shoe
Do not use an compressed air or a dry brush to
clean components of the brake system, use a
vacuum cleaner or the equivalent to avoid
asbestos dust flying.
Caution
Brake fluid
Caution
Exhaust contains toxic gas which may cause
one to lose consciousness and even result in
death.
•Battery emits explosive gases; flame is
strictly prohibited. Keep the place well
ventilated when charging the battery.
•Battery contains sulfuric acid (electrolyte)
which can cause serious burns so be
careful do not be spray on your eyes or
skin. If you get battery acid on your skin,
flush it off immediately with water. If you
get battery acid in your eyes, flush it off
immediately with water, then go to hospital
to see an ophthalmologist.
•If you swallow it by mistake, drink a lot of
water or milk, and take some laxative such
as castor oil or vegetable oil, and then go
to see a doctor.
•Keep electrolyte beyond reach of children.
Gasoline is highly flammable, and may
explode under some conditions, keep it away
from children.
Prolonged contact with used engine oil (or
transmission oil) may cause skin cancer
although it might not be verdict.
We recommend that you wash your hands
with soap and water right after contacting.
Keep the used oil beyond reach of children.
Inhaling asbestos dust may cause disorders
and cancer of the breathing system.
Spilling brake fluid on painted, plastic, or
rubber parts may cause damage to the
parts. Place a clean towel on the
above-mentioned parts for protection when
servicing the brake system. Keep brake fluid
beyond reach of children.
Components of the engine and exhaust
system can become extremely hot after
engine running. They remain very hot even
after the engine has been stopped for some
time. When performing service work on these
parts, wear insulated gloves and wait until
cooling off.
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1. General Information/Trouble Diagnosis
1-3
Service Precautions
• Always use with SANYANG genuine parts and
recommended oils. Using non-designed parts
for SANYANG motorcycle may damage the
motorcycle.
• Special tools are designed for remove and
install of components without damaging the
parts being worked on. Using wrong tools may
result in parts damaged.
• When servicing this motorcycle, use only
metric tools. Metric bolts, nuts, and screws are
not interchangeable with the English system,
using wrong tools and fasteners may damage
this vehicle.
• Clean the outside of the parts or the cover
before removing it from the motorcycle.
Otherwise, dirt and deposit accumulated on
the part's surface may fall into the engine,
chassis, or brake system to cause a damage.
• Wash and clean parts with high ignition point
solvent, and blow dry with compressed air. Pay
special attention to O-rings or oil seals
because most cleaning agents have an
adverse effect on them.
• Never bend or twist a control cable to prevent
stiff control and premature worn out.
• Rubber parts may become deteriorated when
old, and prone to be damaged by solvent and
oil. Check these parts before installation to
make sure that they are in good condition,
replace if necessary.
• When loosening a component which has
different sized fasteners, operate with a
diagonal pattern and work from inside out.
Loosen the small fasteners first. If the bigger
ones are loosen first, small fasteners may
receive too much stress.
• Store complex components such as
transmission parts in the proper assemble
order and tie them together with a wire for
ease of installation later.
• Note the reassemble position of the important
components before disassembling them to
ensure they will be reassembled in correct
dimensions (depth, distance or position).
• Components not to be reused should be
replaced when disassembled including gaskets
metal seal rings, O-rings, oil seals, snap rings,
and split pins.
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1. General Information/Trouble Diagnosis
1-4
• The length of bolts and screws for assemblies,
cover plates or boxes is different from one
another, be sure they are correctly installed. In
case of confusion, Insert the bolt into the hole
to compare its length with other bolts, if its
length out side the hole is the same with other
bolts, it is a correct bolt. Bolts for the same
assembly should have the same length.
• Tighten assemblies with different dimension
fasteners as follows: Tighten all the fasteners
with fingers, then tighten the big ones with
special tool first diagonally from inside toward
outside, important components should be
tightened 2 to 3 times with appropriate
increments to avoid warp unless otherwise
indicated. Bolts and fasteners should be kept
clean and dry. Do not apply oil to the threads.
• When oil seal is installed, fill the groove with
grease, install the oil seal with the name of the
manufacturer facing outside, check the shaft
on which the oil seal is to be installed for
smoothness and for burrs that may damage
the oil seal.
• Remove residues of the old gasket or sealant
before reinstallation, grind with a grindstone if
the contact surface has any damage.
• The ends of rubber hoses (for fuel, vacuum, or
coolant) should be pushed as far as they can
go to their connections so that there is enough
room below the enlarged ends for tightening
the clamps.
• Rubber and plastic boots should be properly
reinstalled to the original correct positions as
designed.
• The tool should be pressed against two (inner
and outer) bearing races when removing a ball
bearing. Damage may result if the tool is
pressed against only one race (either inner
race or outer race). In this case, the bearing
should be replaced. To avoid damaging the
bearing, use equal force on both races.
Both of these examples can result in bearing
damage.
Manufacturer's name
Groove
Clamp
Connector
Boots
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1. General Information/Trouble Diagnosis
1-5
• Lubricate the rotation face with specified
lubricant on the lubrication points before
assembling.
• Check if positions and operation for installed
parts is in correct and properly.
• Make sure service safety each other when
conducting by two persons.
• Note that do not let parts fall down.
• Before battery removal operation, it has to
remove the battery negative (-) cable firstly.
Notre tools like open-end wrench do not
contact with body to prevent from circuit short
and create spark.
• After service completed, make sure all
connection points is secured.
Battery positive (+) cable should be connected
firstly.
And the two posts of battery have to be
greased after connected the cables.
• Make sure that the battery post caps are
located in properly after the battery posts had
been serviced.
• If fuse burned, it has to find out the cause and
solved it. And then replace with specified
capacity fuse.
capacity
verification
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1. General Information/Trouble Diagnosis
1-6
• When separating a connector, it locker has to
be unlocked firstly. Then, conduct the service
operation.
• Do not pull the wires as removing a connector
or wires. Hold the connector body.
• Make sure if the connector pins are bent,
extruded or loosen.
• Insert the connector completely.
If there are two lockers on two connector sides,
make sure the lockers are locked in properly.
Check if any wire loose.
• Check if the connector is covered by the twin
connector boot completely and secured
properly.
• Before terminal connection, check if the boot is
crack or the terminal is loose.
• Insert the terminal completely.
Check if the terminal is covered by the boot.
Do not let boot open facing up.
• Secure wires and wire harnesses to the frame
with respective wire bands at the designated
locations. Tighten the bands so that only the
insulated surfaces contact the wires or wire
harnesses.
• Wire band and wire harness have to be
clamped secured properly.
• Do not squeeze wires against the weld or its
clamp.
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1. General Information/Trouble Diagnosis
1-7
• Do not let the wire harness contact with
rotating, moving or vibrating components as
routing the harness.
• Keep wire harnesses far away from the hot
parts.
•Route wire harnesses to avoid sharp edges or
corners and also avoid the projected ends of
bolts and screws.
• Route harnesses so that they neither pull too
tight nor have excessive slack.
• Protect wires or wire harnesses with electrical
tape or tube if they contact a sharp edge or
corner. Thoroughly clean the surface where
tape is to be applied.
• Secure the rubber boot firmly as applying it on
wire harness.
• Never use wires or harnesses which insulation
has been broken. Wrap electrical tape
around the damaged parts or replace them.
• Never clamp or squeeze the wire harness as
installing other components.
NEVER TOUCH
NEVER TOO
TIGHT
Never clamp or
squeeze the wire
harness
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Contents

1. General Information/Trouble Diagnosis
1-8
• Do not let the wire harness been twisted as
installation.
•Wire harnesses routed along the handlebar
should not be pulled too tight or have excessive
slack, be rubbed against or interfere with
adjacent or surrounding parts in all steering
positions.
•Before operating a test instrument, operator
should read the operation manual of the
instrument. And then, conduct test in
accordance with the instruction.
• With sand paper to clean rust on connector
pins/terminals if found. And then conduct
connection operation later.
Do you know how to set the
instrument to its measurement
position and the insert
locations of its two probes?
Clean rust
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1. General Information/Trouble Diagnosis
1-9
Specifications
Maker SANYANG MODEL HF12W-6
Overall Length 1945 mm Front TELESCOPE
Overall Width 700 mm Suspension
System Rear UNlT SWING
Overall Height 1160 mm Front 100 / 90-12 (61L)
DIMENSION
Wheel Base 1335 mm Tire
Specifications Rear 130 / 70 –12 (64L)
Front 48 kg
Rear 75 kg Front DISK (ø 273 mm)
Curb
Weight Total 123 kg
Brake System
Rear DRUM (ø 130 mm)
Passengers/
Weight Two /110 kg Max. Speed 96 km/hr Above
Front 84 kg
PERFOR
MANCE Climb Ability 28° Below
Rear 162 kg Primary
Reduction BELT
WEIGHT
Total
Weight
Total 246 kg Secondary
Reduction GEAR
Type 4-STROKE ENGINE Clutch Centrifugal, dry type
Installation and
arrangement Vertical, below center, incline 80°
Reduction
Transmission C.V.T.
Fuel Used Unleaded Speedometer 0 ~ 140 km/hr
Cycle/Cooling 4-stroke/forced air
cooled Horn 70~90 dB/A
Bore 52.4 mm Muffler Expansion & Pulse Type
Stroke 57.8 mm
Exhaust Pipe Position
and Direction Right side, and Backward
Cylinder
Number/Arran
gement Single Cylinder Lubrication System Separated-lubrication
Displacement 124.6 cc Solid
Particulate -
Compression
Ratio 10.3 : 1 CO Below 4 %
Max. HP 11.0 ps / 8250 rpm
Exhaust
Concentration
HC Below 2000 ppm
Max. Torque 1.0 kg-m / 7000 rpm E.E.C. NO
Ignition C.D.I. P.C.V. NO
ENGINE
Starting System Power & Foot Catalytic reaction
control system NO
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1. General Information/Trouble Diagnosis
1-10
Torque Values (Engine)
Item Q’ty
Thread Dia.
(mm) Torque Value(Kg-m) Remarks
Cylinder head bolts 4 6 1.0~1.4
Cylinder head nuts 4 8 2.0~2.4
Cylinder/cylinder head two-ends
bolts 4 8 0.7~1.1 Tighten to crankcase
Cylinder head left bolts 4 6 1.0~1.4
Valve adjustment fixing nuts 4 5 0.7~1.1 Apply oil to thread
Cylinder head left cover bolts 2 6 1.0~1.4
Spark plug 1 10 1.0~1.2
Carburetor heat protector
connecting nuts 2 6 0.7~1.1
Engine oil draining plug 1 12 3.5~4.5
Engine oil strainer cap 1 30 1.0~2.0
Gear oil draining plug 1 8 0.8~1.2
Gear oil filling bolt 1 10 1.0~1.4
Oil pump screws 3 3 0.1~0.3
Engine left side cover bolts 8 6 1.0~1.5 Rubber washer attached
Camshaft chain tensioner bolt 1 6 0.35~0.5 Hex socket bolt
Camshaft chain adjuster bolts 1 6 0.8~1.2
Clutch driving plate nut 1 28 5.0~6.0
Clutch outer bracket nut 1 12 5.0~6.0
Driving disk nut 1 12 5.0~6.0
Flywheel nut 1 12 5.0~6.0
One-way clutch tighten bolts 3 6 1.0~1.4 Apply locking sealant
One-way clutch nut 1 22 9.0~10.0 Apply oil to thread
Crankcase bolts/right crank
cover bolt 12 8 1.5~2.0
Gear box cap bolts 7 8 2.0~2.4
Exhaust pipe bolts 2 8 3.0~3.6
Exhaust pipe connection nut 2 7 0.5~1.0
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1. General Information/Trouble Diagnosis
1-11
Torque Values (Frame)
Item Q’ty
Thread Dia.
(mm) Torque Value(Kg-m) Remarks
Mounting bolt for steering
handlebar 1 10 4.0~5.0
Mounting nut for steering rod 1 25.4 1.0~2.0
Cone seat for steering rod 1 25.4 0.2~0.3
Front wheel shaft nut 1 12 5.0~7.0
Rear wheel shaft nut 1 16 11.0~13.0
Wheel hub/rim mounting nuts 1 5 0.15~0.3
Speedometer cable locking
screw 4 8 2.4~3.0
Front shock absorber mounting
bolts 1 10 3.5~4.5
Rear shock absorber upper
connection bolt 1 8 2.4~3.0
Rear shock absorber upper
connection bolt 4 6 1.0~1.4
Brake lever bolts 2 4 0.1~0.2
Front brake hose bolts 2 6 1.0~1.4
Front brake air-bleeding valve 2 10 3.0~4.0
Front brake disc mounting bolts 1 6 0.7~1.1
Front brake clipper mounting
bolts 4 8 4.0~4.5
Drum brake arm bolts
(front/rear) 2 8 2.9~3.5
Engine suspension bracket
bolts 2 10 4.5~5.5
On frame side
Engine connection bolt 1 12 5.0~7.0 On engine side
Main standard nut 1 10 3.5~4.5
Foot-starting lever bolt 1 6 1.6~1.8
Air cleaner bolts 2 6 1.0~1.4
The torque values listed in above table are for more important tighten torque values. Please see
standard values for not listed in the table.
Standard Torque Values for Reference
Type Tighten Torque Type Tighten Torque
5mm bolt、nut 0.45~0.60 kgf-m 3mm screw 0.05~0.08 kgf-m
6mm bolt、nut 0.80~1.20 kgf-m 4mm screw 0.10~0.15 kgf-m
8mm bolt、nut 1.80~2.50 kgf-m 5mm screw 0.35~0.50 kgf-m
10mm bolt、nut 3.00~4.00 kgf-m 6mm screw、SH nut 0.70~1.10 kgf-m
12mm bolt、nut 5.00~6.00 kgf-m 6mm bolt、nut 1.00~1.40 kgf-m
8mm bolt、nut 2.40~3.00 kgf-m
10mm bolt、nut 3.50~4.50 kgf-m
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1. General Information/Trouble Diagnosis
1-12
Troubles Diagnosis
A. Engine hard to start or can not be started
Cylinder compression
pressure normal
Check and adjustment Fault condition Probable causes
Loosen carburetor drain bolt
to check if there is gasoline
inside the carburetor
Fuel supplied tom
carburetor sufficient No fuel is supplied to
carburetor
Remove spark plug, install it
into spark plug cap, and
perform a spark test against
engine ground.
Perform cylinder
compression pressure test.
Check if sparks Weak sparks, no spark
at all
Low compression pressure
or no pressure
Re-start by following the
starting procedures
No ignition There are some signs of
ignition, nut engine can
not be started
Remove the spark plug
again and check it.
Remove carburetor after 30
minutes and connect a hose
onto fuel rich circuit. Then
blow the hose with air
Dry spark plug Wet spark plug
Blowing in normal Blowing clogged
1.No fuel in fuel tank
2.Check if the pipes, fuel tank to
carburetor and intake vacuum, are
clogged.
3.Float valve clogged
4.Lines in fuel tank evaporation system
clogged
5.Malfunction of fuel pump
6.Loosen or damaged fuel pump vacuum
hose
7.Fuel filter clogged
1. Malfunction of spark plug
2. Spark plug foul
3. Malfunction of CDI set
4. Malfunction of AC generator
5. Ignition coil is in open or short circuit
6. Ignition coil leads open or short circuit
7. Malfunction of main switch
1. Piston ring seized
2. Malfunction of cylinder valves
3. Worn cylinder and piston ring
4. Cylinder gasket leak
5. Sand hole in compression parts
1. Malfunction of throttle valve operation
2. Air sucked into intake manifold
3. Incorrect ignition timing
1. Fuel level in carburetor too high
2. Malfunction of throttle valve operation
3. Throttle valve opening too wide
1. Malfunction of automatic by- starter
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1. General Information/Trouble Diagnosis
1-13
B. Engine run sluggish (Speed does not pick up, lack of power)
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Check and adjustment Fault condition Probable causes
Try gradual acceleration
and check engine speed
Engine speed can be
increased. Engine speed can not
be increased.
Check ignition timing
(Using ignition lamp)
Check cylinder compression
pressure (using compression
pressure gauge)
Ignition timing correct Incorrect ignition timing
Compression pressure correct No compression pressure
Check if carburetor jet is
clogged
No clogged Clogged
Remove spark plug
Check if engine over heat
No foul or discoloration Fouled and discoloration
No knock Knock
0. Air cleaner clogged
1. Poor fuel supply
2. Lines in fuel tank evaporation
system clogged
3. Exhaust pipe clogged
4. Fuel level too low in carburetor
5. Fuel nozzle clogged in carburetor.
1. Malfunction of CDI
2. Malfunction of AC alternator
1. Cylinder & piston ring worn out
2. Cylinder gasket leaked
3. Sand hole in compression parts
4. Valve deterioration
5. Seized piston ring
1. Remove foreign
1. Remove dirt
2. Incorrect spark plug heat range
1. Piston and cylinder worn out
2. Lean mixture
3. Poor fuel quality
4. Too much carbon deposited in
combustion chamber
5. Ignition timing too advanced
6. Poor circuit on the cooling system
Normal Engine overheat
Continually drive in
acceleration or high speed
1. Too much carbon deposited in
combustion chamber
2. Lean mixture
3. Poor fuel quality
4. Ignition timing too advanced

1. General Information/Trouble Diagnosis
1-14
C. Engine runs sluggish (especially in low speed and idling)
D. Engine runs sluggish (High speed)
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Check ignition timing (using
ignition lamp)
Good spark Poor
No air sucked Air sucked
Good Poor
Abnormal
Air sucked through carburetor
gasket
Adjust the air screw of
carburetor
Remove spark plug, install
spark plug into spark plug cap
and perform spark test
against engine ground
Normal
Check and adjustment Fault condition Probable causes
Check for fuel supplying system
in automatic fuel cup
Check if carburetor clogged
1. Incorrect ignition timing (malfunction of
CDI or AC alternator)
1. Rich mixture (loosen the screw)
2. Lean mixture (tighten the screw)
1. Poor heat insulation gasket
2. Carburetor lock loose
3. Poor intake gasket
4. Poor carburetor O-ring
5. Vacuum hose crack
1. Spark plug fouled
2. Malfunction of CDI
3. Malfunction of AC generator
4. Malfunction of ignition coil
5. Open or short circuit in spark plug
leads
6. Malfunction of main switch
1. Insufficient fuel in fuel tank
2. Fuel filter clogged
3. Restricted fuel tank vent
Good Poor
Check and adjustment Fault condition Probable causes
Check ignition timing
1. Malfunction of CDI
2. Malfunction of AC alternator
Normal Abnormal
No clogged Clogged 1. Cleaning

1. General Information/Trouble Diagnosis
1-15
E. Clutch, driving and driving pulley
1. Clutch weights spring broken
2. Clutch outer stuck with clutch weights
3. Connection parts in clutch and shaft worn out or
burned
Engine can be started but
motorcycle can not be moved.
FAULT CONDITIONS PROBABLE CAUSES
1. Drive belt worn out or deformation
2. Ramp plate of movable drive face damaged
3. Driving pulley spring broken
4. Clutch weights broken
5. Drive slide-shaft gear groove broken
6. Transmission gear damaged
Engine running and misfire as
motorcycle initial forward moving
or jumping suddenly (rear wheel
rotating as engine in running)
Poor initial driving ( Poor climbing
performance)
1. Drive belt worn out or deformation
2. Weight roller worn out
3. Movable drive face shaft worn out
4. Driven pulley spring deformation
5. Driven pulley shaft worn out
6. Greased in drive belt and driven face.
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